Printing layer in response to substrate contour

ABSTRACT

A method of printing a three-dimensional structure onto a base having irregularities on the surface is disclosed. A sensing device determines the depth of the irregularity on the surface. A computing system receives an image file including a predetermined thickness of a layer to be printed onto the base. The predetermined thickness is adjusted based on the depth of the irregularity. A printing device prints a layer onto the base having the adjusted predetermined thickness print on the irregularity to make the surface substantially smooth.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/287,010, filed on Oct. 6, 2016, which claims priority to U.S.Provisional Patent Application No. 62/248,086, filed on Oct. 29, 2015,both of which are incorporated herein by reference.

BACKGROUND

The present embodiments relate generally to three-dimensional printingsystems and methods.

Three-dimensional printing systems and methods may be associated withvarious technologies, including fused deposition modeling (FDM),electron beam freeform fabrication (EBF), selective laser sintering(SLS) as well as other kinds of three-dimensional printing technologies.

Structures formed from three-dimensional printing systems can be usedwith objects formed by other manufacturing techniques. These includetextile materials used in various articles of footwear and/or articlesof apparel.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of an embodiment of components of a printingsystem as well as several articles that may be used with the printingsystem;

FIG. 2 is an embodiment of a process of printing on an article havingirregularities;

FIG. 3 is a schematic view of an embodiment of an article havingirregularities on the surface;

FIG. 4 is an isometric view of an embodiment of an irregularity having adeep groove;

FIG. 5 is an isometric view of an embodiment of an irregularity having adeep groove of FIG. 4 shown at the pixel level;

FIG. 6 is an embodiment of a table showing the pixel locations and depthof the irregularity of FIG. 5;

FIG. 7 is an isometric view of an embodiment of an irregularity having ashallow groove;

FIG. 8 is an isometric view of an embodiment of an irregularity having ashallow groove of FIG. 7 shown at pixel scale;

FIG. 9 is an embodiment of a table showing the pixel locations and depthof the irregularity of FIG. 8;

FIG. 10 is a schematic view of an embodiment of an article of differentirregularities;

FIG. 11 is a schematic view of an embodiment of a first layer printed onan article of FIG. 10;

FIG. 12 is a schematic view of an embodiment of a second layer printedon the first layer of FIG. 11;

FIG. 13 is a schematic view of an embodiment of a third layer printed onthe second layer of FIG. 12;

FIG. 14 is a schematic view of an embodiment of multiple layers printedon an article; and

FIG. 15 is another embodiment of a process of printing on an articlehaving irregularities.

DETAILED DESCRIPTION

In one aspect, a method of printing onto a base by receiving the base ona platform and detecting a depth of a cavity on the base with a sensingdevice. Further, receiving an image file of a structure to be formed onthe base. The image file includes a predetermined thickness of a layer.The method further generates a modified image file using the depth ofthe cavity, and the modified image file includes a first adjustedthickness for a portion of the layer corresponding to the cavity. Thenprinting a base layer directly onto the base using the modified imagefile. The base layer includes a first adjusted portion printed withinthe first cavity and the first adjusted portion has the first adjustedthickness.

In another aspect, a method for printing a three-dimensional structureonto a base by receiving an image file corresponding to atwo-dimensional representation of the three-dimensional structure andthe image file including a predetermined thickness of a layer. Further,receiving the base having a first cavity with a first depth and a secondcavity with a second depth. The method further detecting the first depthof the first cavity and detecting the second depth of the second cavitywith a sensing device, and the second depth is greater than the firstdepth. Then, generating a modified image file using the first depth andthe second depth and the modified image file includes a first adjustedthickness of a first portion of the layer corresponding to the firstcavity and a second adjusted thickness of a second portion of the layercorresponding to the second cavity. Then printing a base layer directlyonto the base using the modified image file. The base layer includes afirst adjusted portion printed within the first cavity, and the firstadjusted portion has the first adjusted thickness and fills the firstcavity. The base layer further includes a second adjusted portionprinted within the second cavity, and the second adjusted portion hasthe second adjusted thickness and partially fills the second cavitythereby forming a third cavity that extends from a top surface of thebase layer to a top surface of the second adjusted portion.

In another aspect, a system for printing onto a base having a controlsystem and printing device. The control system configured to receiveinformation about a depth of a cavity on a surface of the base andreceive an image file of a structure to be printed on the base. Thecontrol system further adjusts the image file based on the depth of thecavity and generates an adjusted image file, which is transmitted to theprinting device. The printing device configures to receive the adjustedimage file and print a base layer directly onto the base using theadjusted image file.

Other systems, methods, features, and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

FIG. 1 illustrates a schematic view of an exemplary embodiment ofcomponents of printing system 100. In some embodiments, printing system100 may include several components for facilitating the printing ofobjects (e.g., parts, elements, features, or structures, etc.) onsubstrate 102. In some embodiments, printing system 100 includesprinting device 110, and computing system 120 with network 130. Thesecomponents will be explained further in detail below. For purposes ofillustration, only some components of printing system 100 are depictedin FIG. 1 and described below. It will be understood that in otherembodiments, printing system 100 may include additional provisions.

Printing system 100 may utilize various types of printing techniques.These can include, but are not limited to, toner-based printing, liquidinkjet printing, solid ink printing, dye-sublimation printing, inklessprinting (including thermal printing and UV printing),MicroElectroMechanical Systems (MEMS) jet printing technologies as wellas any other methods of printing. In some cases, printing system 100 maymake use of a combination of two or more different printing techniques.The type of printing technique used may vary according to factorsincluding, but not limited to, material of the target article, size,and/or geometry of the target article, desired properties of the printedimage (such as durability, color, ink density, etc.) as well as printingspeed, printing costs, and maintenance requirements.

In some embodiments, printing system 100 includes printing device 110.In some embodiments, printing device 110 may include features such ashousing component 112, tray 114, printhead 116, and sensing device 132.Housing component 112 may be used to support other components, devices,or systems of printing system 100. In some embodiments, housingcomponent 112 may include features to move substrate 102 duringoperation. In some embodiments, the shape and size of housing component112 may vary according to factors that include the desired footprint forprinting device 110, the size and shape of substrate 102 or multiplesubstrates, the size and shape of features that may be formed onsubstrate 102 as well as possibly other factors.

In some embodiments, printing device 110 may include provisions such asa table, platform, tray, or similar component to support, retain, and/orhold substrate 102. In some embodiments, tray 114 may be used toposition substrate 102 while layer materials are being deposited ontosubstrate 102 by a printhead 116. In some embodiments, tray 114 mayretain a single substrate 102. In some other embodiments, tray 114 maybe so dimensioned and sized such that it can retain additionalsubstrates 104, as shown.

Some embodiments may include provisions to facilitate forming aselectively printed design feature on substrate 102. In someembodiments, printing device 110 may include provisions for depositing alayer material onto substrate 102, such as printhead 116. In someembodiments, printing device 110 may include provisions for applyingradiant energy, such as an ultraviolet (UV) lamp (not shown). In oneembodiment, printing device 110 includes printhead 116 and a UV lamp totransform a physical property of a layer material and form a selectivelyprinted design feature on substrate 102.

In some embodiments, printhead 116 could be used to deposit an ink layerin order to form a selectively printed design feature onto substrate102. In some embodiments, printhead 116 could be configured to move anddeposit an ink layer within housing component 112 in a horizontaldirection (e.g., front-back and/or left-right with respect to housingcomponent 112) onto substrate 102.

In some embodiments, a printing device could include provisions for asensing device that detects various kinds of information. In someembodiments, a printing device could include provisions for detectingdepth information (e.g., the depth of contours in a surface). Suchprovisions may include, but are not limited to, optical sensing devicesas well as other kinds of depth sensing devices that may be known in theart.

In the exemplary embodiment shown in FIG. 1, printing system 100includes sensing device 132 to detect optical or visual information.Specifically, sensing device 132 may be an optical sensing device. Asdiscussed further below, the optical information captured by sensingdevice 132 could be used to determine depth information of a nearbysurface.

In different embodiments, the location of the sensing device could vary.Sensing device 132 could be static or moving. In some embodiments, forexample, sensing device 132 could be stationary and could be disposedabove printing device 110. This position could maximize the ability tocapture large sections of substrate 102. In some embodiments, sensingdevice 132 could be located by a separate positioning assembly (notshown). In other embodiments, sensing device 132 could be disposed on orwithin housing component 112. In the exemplary embodiment, sensingdevice 132 could be disposed near, or even attached to printhead 116. Asprinthead 116 is moved, sensing device 132 could therefore travel withprinthead 116. Sensing device 132 could move in the same direction asprinthead 116 to detect visual and/or optical information of substrate102. In other embodiments, sensing device 132 could be disposed awayfrom printhead 116. In some cases, sensing device 132 could have a fixedlocation and/or orientation relative to housing component 112. In othercases, sensing device 132 could have an adjustable location and/ororientation and could be movable independently of printhead 116.

Embodiments can include provisions for detecting optical informationabout substrate 102, including depth of any irregularities on thesurface of substrate 102. The irregularities could be recesses,depressions, cavities, holes, gaps, craters, pits, or anyinconsistencies on the surface of the substrate. The substrate could beany article as described in further detail below, or any material thatcould be used as a base or substrate such as metal, any form ofplastics, thermoplastics, or ceramics.

In some embodiments, sensing device 132 may be any kind of device orcombination of devices capable of capturing image information anddetecting the depth of an irregularity on a surface. Examples ofdifferent optical sensing devices that could be used include, but arenot limited to, still-shot cameras, video cameras, digital cameras,non-digital cameras, web cameras (web cams), as well as other kinds ofoptical devices known in the art. The type of optical sensing device maybe selected according to factors such as desired data transfer speeds,system memory allocation, desired temporal resolution for viewing asubstrate, desired spatial resolution for viewing a substrate as well aspossibly other factors. In at least one embodiment, sensing device 132could be an image sensor having a minimal form factor, for example, anoptical sensing device with a complementary metal-oxide-semiconductor(CMOS) image sensor with a footprint on the order of several millimetersor less.

Exemplary image sensing technologies that could be used with sensingdevice 132 include, but are not limited to, semiconductor charge-coupleddevices (CCD), complementary metal-oxide-semiconductor (CMOS) typesensors, N-type metal-oxide-semiconductor (NMOS) type sensors as well aspossibly other kinds of sensors. The type of image sensing technologyused may vary according to factors including optimizing the sensor typecompatible with ambient conditions in printing device 110 (and near orwithin printhead 116), size constraints as well as possibly otherfactors. In some other embodiments, optical sensing devices that detectnon-visible wavelengths (including, for instance, infrared wavelengths)could also be used.

Sensing device 132 may convert optical images into informationtransmitted via electrical signals to one or more systems of printingsystem 100. Upon receiving these electrical signals, the one or moresystems can use this information to determine a variety of informationabout objects that may be visible to sensing device 132.

In different embodiments, detecting the depth of an irregularity on thesurface of a substrate could include using a laser to detect the depth.Different kinds of depth detecting devices or sensors could be utilized.Not just optical sensing devices, but any device designed or configuredto detect the depth of an irregularity on a surface. For example,reflected light wavelengths could be increased when an irregularity orcavity is detected on the surface of the substrate. In otherembodiments, detecting the depth of an irregularity on the surface of asubstrate could include provisions of ultrasonic waves to detect thedepth. Ultrasonic waves could be emitted onto the surface of thesubstrate, and the returning waves could be analyzed. For example, if adefect is present on the surface, the ultrasonic waves could reflectsooner than if there were no defects on the surface. Differentprovisions could be used to detect the depth of an irregularity bycomparing the different reflections on the varying surfaces of thesubstrate. Another example is a measuring device wherein light isprojected upon a substrate being examined and the measurement is made byutilizing interference of light reflected from the substrate todetermine the depth of the irregularity. Another example of detectingthe depth of an irregularity could be spectral reflectioncharacteristics of the return signal are detected and analyzed todetermine the depth of the irregularity. Light is projected onto thesubstrate and any irregularity is detected based on the variation of theintensity of the reflected light. Another example is irradiating a laserbeam to the surface of the article and determining when the reflectedbeam is interrupted temporarily. Any depth detecting device or sensorcould be configured with the printing device to detect the depth of anirregularity on the surface of the substrate.

Some printing systems may include provisions to control and/or receiveinformation from printing device 110. These provisions can includecomputing system 120 and network 130. As used in this detaileddescription and in the claims, “computing system” and its variantsthereof may refer to the computing resources of a single computer, aportion of computing resources of a single computer, and/or two or morecomputers in communication with one another. Any of these resources canbe operated by one or more human users. In some embodiments, computingsystem 120 may include one or more servers. In some cases, a printserver may be primarily responsible for controlling and/or communicatingwith printing device 110, while a separate computer (e.g., desktop,laptops or tablet) may facilitate interactions with a user (not shown).Computing system 120 can also include one or more storage devicesincluding, but not limited to, magnetic, optical, magneto-optical,and/or memory, including volatile memory and non-volatile memory.

As illustrated in FIG. 1, computing system 120 may comprise centralprocessing device 122, visual interface 124 (e.g., a monitor or screen),input devices 126 (e.g., keyboard and mouse), and software for designinga computer-aided design (“CAD”) representation 128 of a printedstructure. In at least some embodiments, the CAD representation 128 of aprinted structure may include not only information about the geometry ofthe structure but also information related to the materials required toprint various portions of the design feature and the number of layersrequired to achieve the structure.

In some embodiments, computing system 120 may be in communication withprinting device 110 through network 130. Network 130 may include anywired or wireless provision that facilitate the exchange of informationbetween computing system 120 and printing device 110. In someembodiments, network 130 may further include various components such asnetwork interface controllers, repeaters, hubs, bridges, switches,routers, modems, and firewalls. In some cases, network 130 may be awireless network that facilitates wireless communication between two ormore systems, devices, and/or components of printing system 100.Examples of wireless networks include, but are not limited to, wirelesspersonal area networks (including, for example, Bluetooth), wirelesslocal area networks (including networks utilizing the IEEE 802.11 WLANstandards), wireless mesh networks, mobile device networks as well asother kinds of wireless networks. In other cases, network 130 could be awired network including networks whose signals are facilitated bytwister pair wires, coaxial cables, and optical fibers. In still othercases, a combination of wired and wireless networks and/or connectionscould be used.

In some embodiments, printed structures may be printed directly to oneor more substrates or articles. The term “articles” is intended toinclude both articles of footwear (e.g., shoes) and articles of apparel(e.g., shirts, pants, etc.). As used throughout this disclosure, theterms “article of footwear” and “footwear” include any footwear and anymaterial associated with footwear, including an upper, and may also beapplied to a variety of athletic footwear types, including baseballshoes, basketball shoes, cross-training shoes, cycling shoes, footballshoes, tennis shoes, soccer shoes, and hiking boots, for example. Asused throughout this disclosure, the terms “article of footwear” and“footwear” also include footwear types that are generally considered tobe nonathletic, formal, or decorative, including dress shoes, loafers,sandals, slippers, boat shoes, and work boots.

While the disclosed embodiments are described in the context offootwear, the disclosed embodiments may further be equally applied toany article of clothing, apparel, or equipment that includes 3Dprinting. For example, the disclosed embodiments may be applied to hats,caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments,athletic support garments, gloves, wrist/arm bands, sleeves, headbands,any knit material, any woven material, any nonwoven material, sportsequipment, etc. Thus, as used throughout this disclosure, the term“article of apparel” may refer to any apparel or clothing, including anyarticle of footwear, as well as hats, caps, shirts, jerseys, jackets,socks, shorts, pants, undergarments, athletic support garments, gloves,wrist/arm bands, sleeves, headbands, any knit material, any wovenmaterial, any nonwoven material, etc. As used throughout thisdisclosure, the terms “article of apparel,” “apparel,” “article offootwear,” and “footwear” may also refer to a textile, natural fabric,synthetic fabric, knit, woven material, nonwoven material, mesh,leather, synthetic leather, polymer, rubber, and foam.

In order to apply printed materials directly to one or more articles,printing device 110 may be capable of printing onto the surfaces ofvarious kinds of materials. Specifically, in some cases, printing device110 may be capable of printing onto the surfaces of various materialssuch as a textile, natural fabric, synthetic fabric, knit, wovenmaterial, nonwoven material, mesh, leather, synthetic leather, polymer,rubber, and foam, or any combination of them, without the need for arelease layer interposed between a substrate and the bottom of theprinted material, and without the need for a perfectly or near-perfectlyflat substrate surface on which to print. For example, the disclosedmethods may include printing a resin, acrylic, thermoplastic material,or ink material onto a fabric, for example, a knit material, where thematerial is adhered/bonded to the fabric and where the material does notgenerally delaminate when flexed, rolled, worked, or subject toadditional assembly processes/steps. As used throughout this disclosure,the term “fabric” may be used to refer generally to materials chosenfrom any textile, natural fabric, synthetic fabric, knit, wovenmaterial, nonwoven material, mesh, leather, synthetic leather, polymers,rubbers, and foam.

Printing system 100 may be operated as follows to providethree-dimensional structures that have been formed using a layeringprocess. Computing system 120 may be used to design a three-dimensionalstructure. This may be accomplished using some type of CAD software, orother kind of software. The design may then be transformed intoinformation that can be interpreted by printing device 110 (or a relatedprint server in communication with printing device 110). The structurecould be any shape or geometry and could be produced from athree-dimensional model or electronic data source.

Although the embodiments shown in the figures depict a system usinginkjet printing technologies, it will be understood that still otherembodiments could incorporate any kind of printing technology ordifferent kinds of three-dimensional printing technologies. Beforeprinting, an article may be placed onto tray 114. Once the printingprocess is initiated (by a user, for example), printing device 110 maybegin depositing material onto the article. This may be accomplished bymoving printhead 116 to build up layers of a structure using depositedmaterial. Generally, embodiments could apply any kind of print materialto a substrate. As used herein, the term “print material” refers to anymaterial that can be printed, and includes inks as well as resins,plastics, or other print materials associated with 2D and/or 3Dprinting. In some embodiments, the materials used in the printingtechnology could be any aqueous ink, dye-based ink, pigment-based ink,solvent-based ink, dye sublimation ink, thermoplastic material, acrylicresin, polyurethane, thermoplastic polyurethane, silicone, or any othercurable substance.

FIG. 2 illustrates an embodiment of a process for printing on an articlehaving irregularities. Generally, one or more of the steps depicted inFIG. 2 may be performed by computing system 120, sensing device 132,and/or any other system or component of printing device 110. In othercases, some of the following steps could be performed by any othersystem or device. In addition, the order of steps could vary in anymanner in other embodiments. In some embodiments, the process of FIG. 2may include additional steps, while in other embodiments some stepsdepicted in FIG. 2 may be optional. For purposes of clarity, thefollowing discussion describes steps in this process as being performedby a control unit. As used herein, the term “control unit” or“electronic control unit” refers to any set of resources (e.g., hardwareand/or software) capable of controlling one or more systems orcomponents. A control unit could be a central processing device, such ascentral processing device 122 shown in FIG. 1. Alternatively, a controlunit could be separate from central processing device 122, and could beintegrated with printing device 110, a remote computing system, and/or aserver of some kind.

In a first step 202, a control unit may receive image informationcorresponding to a surface of substrate 102. In some embodiments, theimage information may be received from one or more sensors, such assensing device 132. The received image information could include anykind of analog and/or digital signal that include information related toone or more images captured by sensing device 132.

In step 204, the control unit may use the image information to determineif the surface is smooth. For example, in some embodiments, the surfaceof substrate 102 may have no irregularities or have a planar surface.Then, printing device 110 proceeds to printing in step 206. If thesurface is not smooth, then the control unit, using image informationprovided by sensing device 132, continues to analyze the image ofsubstrate 102 for surface irregularity in step 208.

In step 210, surface contour map information may be created. The contourmap information may be used to detect the depth of any irregularity andprovide the depth amount of the irregularity on the surface of substrate102. The depth amount or information may be a distance from the surfaceto a viewpoint of sensing device 132. In some embodiments, the surfaceof substrate 102 may be the planar or smooth surface portion ofsubstrate 102. In other embodiments, the surface of substrate 102 may bethe surface of the irregularity of substrate 102. Sensing device 132could detect the depth of the irregularity using any of the technologiesmentioned earlier.

Computing system 120 could receive information to print an image,graphic, or structure on substrate 102. The image, graphic, or structureto be printed could be any 2D layer showing an image or a 3Dstructure/object of some kind. In some embodiments, the information maybe images or graphic files, grayscale files, or any other kinds of filesrepresenting the structure to be printed. Image files may be any kind offile format providing image compression of the structure to be printed.For example, the files could be tagged image file format (tiff), jointphotographic experts group (jpeg), graphics interchange format (gif),portable network graphics (png), bitmap file (bmp), photoshop document(psd), portable document format (pdf) file or any other kind of fileformat providing image compression to reduce the amount of storage spacerequired in computing system 120.

In some embodiments, computing system 120 could receive grayscale filesrepresenting information of a structure to be printed on substrate 102,or it could convert an image file to a grayscale file. The grayscalefile could have any of the file formats previously discussed. Thegrayscale file contains an image in which the value of each pixelcarries intensity information. A grayscale file contains only shades ofgray and no color. In some embodiments, the intensity of light could bemeasured at each pixel to determine the grayscale. The darkest possibleshade is black, which is the total absence of transmitted or reflectedlight or weakest intensity. The lightest possible shade is white, thetotal transmission or reflection of light or strongest intensity. Inother embodiments, the intensity of a pixel could also be expressed inpercentages. The percentile notation is used to denote how much ink isemployed or deposited onto the substrate. For example, 0% intensity of apixel is represented by no print material deposited onto the substrate.Further, 100% intensity of a pixel is represented by a maximum amount ofprint material that could be deposited on the substrate for givensettings or physical constraints of a printing system. Computing system120 could receive any type of information or compute any type of filesto print an image, graphic, or structure on substrate 102.

In the foregoing discussion, layer files could be any graphic or imagefile, grayscale file, or any other kind of file containing informationof a structure to be printed onto a substrate. The layer files maycontain information pertaining to the predetermined thickness for eachlayer. Printing device 110 could print a layer file multiple times tocreate the desired image, graphic, or structure on the substrate. Instep 212, the layer files could be modified to fill the irregularity onthe surface of the substrate with a depositing material. The layer filescould be modified based on the surface contour map information createdin step 210. The control unit may utilize the surface contour mapinformation to modify or adjust the predetermined thickness of a layerfile based on the depth amount of the irregularities. The layer filecould be modified at the position or location of the irregularity. Theother positions or locations of the layer file could maintain theirpredetermined thickness. In step 212, each layer file could be adjustedor modified in a similar manner or could be modified differentlydepending on the depth amount of the irregularity.

In some embodiments, the layer file could contain information in whichthe layer has the same predetermined thickness at all positions orlocations. In other embodiments, the layer file could be a grayscalefile containing information in which the layer has different or varyingpredetermined thicknesses depending on the grayscale of the image. Forexample, the grayscale file could establish a relationship between colorand thickness. For lighter regions of an image, the printer could printthinner layers, and for darker regions of the image, the printer couldprint thicker layers. Printing device 110 could print the grayscale filemultiple times in layers, thereby a three-dimensional structure could beprinted onto the substrate. For example, the grayscale file could have aregion of the image being 0.1 mm thick. That region of the image couldreach a height ranging from 1 mm-3 mm thick. The grayscale file couldcontain any combination of information depending on the structure to beprinted. For example, the grayscale file could have a portion or regionof the image with 40% intensity of a pixel. Then that region of thelayer could be 0.04 mm thick. Printing device 110 could be programmed toprint 10 layers, then that region of the image could be 0.4 mm thickafter printing the same file 10 times. Another region could show 100%intensity of a pixel, and then this portion of the layer could be 0.1 mmthick. Printing device 110 could be programmed to print 10 layers, andthen this region of the image could be 1.0 mm thick after printing thesame file 10 times. Printing device 110 prints the entire grayscale filecontaining different amounts of information for each region, such as 40%intensity in a region and 100% intensity in another region. In oneembodiment, a three-dimensional structure could be printed onto thesubstrate from one single image file, grayscale file, or other filecontaining image information. Computing system 120 could sendinformation to print a predetermined number of layers to achieve thethree-dimensional structure. Computing system 120 could program thethickness of each region to a predetermined thickness depending on theshape of the three-dimensional structure. The grayscale file could bemodified to print onto the substrate and fill the irregularity to makethe substrate substantially planar or smooth. The grayscale files couldbe dynamically modified or adjusted depending on any detection ofirregularities of the surface. Examples of grayscale files representingimages or structures are disclosed in U.S. application Ser. No.15/609,220, filed on May 31, 2017, the entirety of which is incorporatedby reference herein.

Then in step 214, printing device 110 may print each modified layerfile. The control unit may provide the information of the modified layerfiles to printing device 110 via network 130. In some embodiments,printing device 110 may print a first modified layer file directly ontosubstrate 102. The modified layer files could be printed repeatedlyuntil the surface of the substrate is substantially smooth.

FIG. 3 illustrates a schematic view of an article having irregularitieson the surface. In some embodiments, the article may be used as an upperof a shoe. The upper material may be of any type of material, such assynthetic leather, leather, textile, or knit. In the exemplaryembodiment, synthetic leather article 306, hereinafter referred to asarticle 306, may have an irregularity shown as a deep groove 304. Also,article 306 may have an irregularity shown as a shallow groove 302.Throughout article 306, there could be multiple grooves of varyingdepth. The position of shallow groove 302 may be designated by X and Ycoordinates. Similarly, the position of deep groove 304 and othergrooves may be designated by X and Y coordinates.

As shown in FIGS. 4 and 5, article 306 has a deep groove 304. FIG. 5illustrates an enlarged view 500 of deep groove 304. FIG. 5 shows across-section of deep groove 304. Sensing device 132 may detect thedepth of deep groove 304 by providing optical information to the controlunit. In some embodiments, article 306 could have a size of 11×16inches. The control unit and sensing device 132 could convert thearticle size to an image size representing the image in pixels. It willbe understood that the size of each pixel can be varied in differentembodiments. Therefore, an article size of 11×16 inches could have animage size of 3300×4800 pixels. FIG. 5 shows pixels at the X coordinateof 2375. X=2375 represents the 2375^(th) pixel from the reference pointof an edge of the article. For purposes of clarity, the Y coordinatewill be discussed at the first 5 pixel locations. As shown in FIG. 5,since deep groove 304 has a similar depth throughout the X plane, only afew pixel locations will be discussed.

FIG. 6 shows the coordinate locations of deep groove 304 at the Xcoordinate of 2375. At pixel location 502, the X coordinate is equal to2375, and the Y coordinate is equal to 3600. At this pixel location, thedepth of the irregularity is 12 units deep. At pixel location 504, the Xcoordinate is equal to 2375, and the Y coordinate is equal to 3601. Atthis pixel location, the depth of the irregularity is 12 units deep. Atpixel location 506, the X coordinate is equal to 2375, and the Ycoordinate is equal to 3602. At this pixel location, the depth of theirregularity is 12 units deep. At pixel location 508, the X coordinateis equal to 2375, and the Y coordinate is equal to 3603. At this pixellocation, the depth of the irregularity is 12 units deep. At pixellocation 510, the X coordinate is equal to 2375, and the Y coordinate isequal to 3604. At this pixel location, the depth of the irregularity is12 units deep. The unit of depth of each pixel may correspond to alinear dimension of a pixel. In some cases, each unit of depth may beequal in magnitude to the width of a pixel. In other cases, a unit ofdepth could be less than or greater than the width of a pixel. Thissurface image information could be generated by using sensing device 132and computing system 120 to determine the depth of deep groove 304.

Referring to FIG. 2, in step 208, the surface image information could beanalyzed by the control unit. Throughout this detailed description andclaims, the control unit may utilize the sensing device 132, computingsystem 120, printing device 110, and/or a combination of them to analyzethe surface image information. In step 210, surface contour mapinformation may be created, as shown in FIG. 5. The article size couldbe converted to the image size represented by pixels. The location ofthe irregularity or cavity could be defined by the pixel coordinates.For example, FIG. 5 shows the deep groove 304 at pixel location 502having coordinates of X=2375 and Y=3600. The control unit could detectthe depth of the irregularity or cavity at each pixel location using anyof the depth detecting technologies previously discussed. For example,FIGS. 5 and 6 show the depth of the irregularity as 12 units deep ateach of the pixel locations. The depth could be a distance from the topof the surface of article 306 to the bottom of the irregularity orcavity.

In step 212, the predetermined thickness of a layer file may be adjustedor modified to compensate for any irregularities on the surface ofarticle 306. The control unit may dynamically modify a predeterminedthickness of a layer file to be printed on article 306 based on thedepth of the cavity of deep groove 304. In an exemplary embodiment, thecontrol unit may correct for the surface being moderately non-planar byprinting the modified layer to fill in the irregularity or cavity. Thecontrol unit could modify a certain number of layer files as needed tofill in the irregularity or cavity to make the article smooth so thatprinting device 110 could print an unmodified layer file on a smoothsurface.

As shown in FIGS. 7 and 8, article 306 has an irregularity shown asshallow groove 302. FIG. 8 illustrates an enlarged view 800 of shallowgroove 302. FIG. 8 shows a cross-section of shallow groove 302. Sensingdevice 132 may detect the depth of shallow groove 302 by providingoptical information to the control unit. In some embodiments, article306 could have a size of 11×16 inches. The control unit and sensingdevice 132 could convert the article size to an image size representedby pixels. Therefore, an article size of 11×16 inches could have animage size of 3300×4800 pixels. FIG. 8 shows pixels at the X coordinateof 2550. X=2550 represents the 2550^(th) pixel from the reference pointof an edge of the article. For purposes of clarity, the Y coordinatewill be discussed showing the varying depths of shallow groove 302.

FIG. 9 shows the coordinate locations of shallow groove 302 at the Xcoordinate of 2550. At pixel location 802, the X coordinate is equal to2550, and the Y coordinate is equal to 1180. At this pixel location, thedepth of the irregularity is 1 unit deep. At pixel location 804, the Xcoordinate is equal to 2550, and the Y coordinate is equal to 1181. Atthis pixel location, the depth of the irregularity is 1 unit deep. Atpixel location 806, the X coordinate is equal to 2550, and the Ycoordinate is equal to 1182. At this pixel location, the depth of theirregularity is 2 units deep. At pixel location 808, the X coordinate isequal to 2550, and the Y coordinate is equal to 1183. At this pixellocation, the depth of the irregularity is 2 units deep. At pixellocation 810, the X coordinate is equal to 2550, and the Y coordinate isequal to 1184. At this pixel location, the depth of the irregularity is2 units deep. At pixel location 812, the X coordinate is equal to 2550,and the Y coordinate is equal to 1185. At this pixel location, the depthof the irregularity is 2 units deep. At pixel location 814, the Xcoordinate is equal to 2550, and the Y coordinate is equal to 1186. Atthis pixel location, the depth of the irregularity is 3 units deep. Atpixel location 816, the X coordinate is equal to 2550, and the Ycoordinate is equal to 1187. At this pixel location, the depth of theirregularity is 3 units deep. The unit of depth of each pixel maycorrespond to a linear dimension of a pixel. In some cases, each unit ofdepth may have the same width of a pixel. This surface image informationcould be generated by using sensing device 132 and computing system 120to determine the depth of shallow groove 302.

Referring to FIG. 2, in step 208, the surface image information could beanalyzed by the control unit. In step 210, surface contour mapinformation may be created, as shown in FIG. 8. The article size couldbe converted to the image size represented by pixels. The location ofthe irregularity or cavity could be defined by the pixel coordinates.For example, FIG. 8 shows shallow groove 302 at pixel location 802having coordinates of X=2550 and Y=1180. The control unit could detectthe depth of the irregularity or cavity at each pixel location using anyof the depth detecting technologies previously discussed. For example,FIGS. 8 and 9 show the depth of the irregularity having varying depthsat each of the pixel locations. At pixel location 804, the depth of theirregularity is 1 unit deep. Shallow groove 302 also shows at pixellocation 814, the depth of the irregularity as 3 units deep. The depthcould be a distance from the top of the surface of article 306 to thebottom of the irregularity or cavity. The control unit could determinethe depth of a cavity even if the cavity has varying depths.

In step 212, the predetermined thickness of a layer file may be adjustedor modified to compensate for any irregularities on the surface ofarticle 306. The control unit may dynamically modify a predeterminedthickness of a layer file to be printed on article 306 based on thedepth of the cavity of shallow groove 302. In an exemplary embodiment,the control unit may correct for the surface being slightly non-planarby printing the modified layer to fill in the cavity. The control unitcould modify a certain number of layer files as needed to fill in theirregularity or cavity to make the article smooth so that printingdevice 110 could print an unmodified layer file on a smooth surface.

FIG. 10 illustrates a schematic view of an article having differentirregularities. Article 1002 could have an irregularity with shallowcavity 1012, moderate cavity 1014 and deep cavity 1016. As discussedabove, the depth of the irregularity could be represented by units ofdepth that may correspond to a linear dimension of a pixel. Shallowcavity 1012 has shallow depth 1018 with a depth of one unit. Moderatecavity 1014 has moderate depth 1020 with a depth of 3 units. Deep cavity1016 has deep depth 1022 with a depth of 12 units. In some embodiments,sensing device 132 and computing system 120 could detect the depth of acavity on the surface of article 1002. The control unit may adjust apredetermined thickness of a layer file to be printed on article 1002based on the depth of the cavities on the surface.

FIGS. 11-14 illustrate a schematic view of multiple layers printed onarticle 1002. In one embodiment, the layer files to create an image,graphic, or structure has predetermined thickness 1034. Some of thelayers are printed from layer files having predetermined thickness 1034.Other layers are printed from modified layer files that include adjustedpredetermined thicknesses or modified thicknesses to compensate for thedifferent irregularities on the surface of article 1002. Printing device110 could print any number of layers from layer files or modified layerfiles or a combination of layer files and modified layer files to createa desired image, graphic, or structure on article 1002.

FIG. 11 illustrates a schematic view of first layer 1004 printed onarticle 1002. As used herein and throughout this description, each layercould have an upper surface or top surface which corresponds to theexposed portion of the layer. The exposed portion could be covered byanother layer or remain exposed. Also, each layer could have a lowersurface or bottom surface, opposite the upper surface, which correspondsto the portion of the layer adjacent the substrate or the exposedportion of a layer which has already been printed. A base layer could beadjacent the substrate by printing the base layer directly onto thesubstrate. Any subsequent layer could be adjacent a previously printedlayer by printing the subsequent layer directly onto the previouslyprinted layer.

First layer 1004 is printed from a modified layer file that haspredetermined thickness 1034 and multiple modified thicknesses. Firstportion 1036 of first layer 1004 has shallow modified thickness 1024 tofill shallow cavity 1012. Further, second portion 1038 of first layer1004 has moderate modified thickness 1026 to fill moderate cavity 1014.To partially fill deep cavity 1016, third portion 1040 of first layer1004 has deep modified thickness 1028. Deep cavity 1016 is partiallyfilled thereby forming another cavity with thickness 1030 which extendsfrom a top surface of first layer 1004 to a top surface of deep modifiedthickness 1028. Since first layer 1004 may not completely fill deepcavity 1016, another layer representing information from a modifiedlayer file could be printed on the top surface of first layer 1004.

After first layer 1004 has been printed, portions of first layer 1004could be continuous or flat. First portion 1036 shows shallow cavity1012 completely filled with first layer 1004 which has upper surface1025. Fourth portion 1029 shows a non-adjusted portion of first layer1004 which has predetermined thickness 1034 with predetermined thicknessupper surface 1027. Since shallow cavity 1012 is completely filled,upper surface 1025 is flush with predetermined thickness upper surface1027 to provide a smooth and continuous surface from first portion 1036to fourth portion 1029.

Upper surface 1025 and predetermined thickness upper surface 1027 are inthe same plane providing a smooth flat surface without any cavities orirregularities. A subsequent layer printed onto first layer 1004 couldhave a portion of the layer adjacent to first portion 1036 and fourthportion 1029 having the predetermined thickness. Fifth portion 1043shown in FIG. 12, shows second layer 1006 with predetermined thickness1034. Since there were no cavities or irregularities detected at fifthportion 1043, that portion of the layer file was not modified andprinting device 110 could print that portion of second layer 1006directly onto the smooth portion of the top surface of first layer 1004.

FIG. 12 illustrates a schematic view of second layer 1006 printed ontothe top surface of first layer 1004. Second layer 1006 is printed from amodified layer file that has predetermined thickness 1034 and modifiedthickness 1032. Second layer 1006 has predetermined thickness 1034 onthe smooth surface portions of first layer 1004. Portion 1042 of secondlayer 1006 has modified thickness 1032 to fill the remaining portion ofdeep cavity 1016. Since first layer 1004 may be substantially smooth atportions around shallow cavity 1012 and moderate cavity 1014, secondlayer 1006 may print predetermined thickness 1034 directly onto thesurface of first layer 1004. Each layer file could be modified oradjusted to compensate for irregularities found on the surface of thearticle. A modified layer file could have an adjusted predeterminedthickness at the location or position of the irregularity.

FIG. 13 illustrates a schematic view of third layer 1008 printed ontothe top surface of second layer 1006. Third layer 1008 is printed from alayer file having predetermined thickness 1034. Since second layer 1006may be substantially smooth or flat, the layer file was not modified andprinting device 110 could print third layer 1008 directly onto the topsurface of second layer 1006 without adjusting a predeterminedthickness.

FIG. 14 illustrates a schematic view of performance ribs 1010 printed onarticle 1002. In some embodiments, since third layer 1008 may besubstantially smooth, printing device 110 may print performance ribs1010 directly onto third layer 1008 without adjusting a predeterminedthickness of the layer file for performance ribs 1010. In otherembodiments, other layers may be printed from layer files onto thirdlayer 1008 to create an image, graphic, or structure.

FIG. 15 illustrates another embodiment of a process for printing on anarticle having irregularities. Process for printing 1500 shows thatafter every layer is printed, the resulting surface could be analyzedagain to determine the depth of any irregularity on the surface andmodify the next layer file to compensate for any irregularity. In step1502, printing device 110 may print a selected layer (e.g., an Nth layerof the layer file). The selected layer could be substrate 102 placed ontray 114. Also, the selected layer could be any intervening layer informing the desired image, graphic, or structure. In step 1504, acontrol unit may receive image information corresponding to a surface ofthe selected layer. In some embodiments, the image information may bereceived from one or more sensors, such as sensing device 132. Thereceived image information could include any kind of analog and/ordigital signal that include information related to one or more imagescaptured by sensing device 132.

In step 1506, surface contour map information of the selected layer maybe created. The contour map information may be used to detect the depthof any irregularity and provide the depth amount of irregularities onthe surface of substrate 102. The depth amount or information may be adistance from the surface to a viewpoint of sensing device 132. In someembodiments, the surface of substrate 102 may be the planar or smoothsurface portion of substrate 102. In other embodiments, the surface ofsubstrate 102 may be the surface of the irregularity of substrate 102.Sensing device 132 could detect the depth of the irregularity using anyof the technologies mentioned earlier.

In step 1508, the control unit could modify the next layer file usingthe contour map information. In some embodiments, the layer files couldbe image files, grayscale files, or any other kind of information files,as previously discussed, of the structure to be printed. The next layerfile could be modified to fill the irregularity on the surface of thesubstrate with a depositing material. The layer files could containinformation pertaining to the predetermined thickness for each layer.The next layer file could be modified based on the surface contour mapinformation created in step 1506. The control unit may utilize thesurface contour map information to modify or adjust the predeterminedthickness of the next layer file based on the depth amount of theirregularities. The next layer file could be modified at the position orlocation of the irregularity. The other positions or locations of thenext layer file could maintain their predetermined thickness. In step1508, the next layer file could be adjusted or modified in a similarmanner as the previous layer file or could be modified differentlydepending on the depth amount of the irregularity. The modified layercould be printed onto the selected layer and fill the cavity orirregularity to make the substrate substantially smooth.

The control unit could contain information pertaining to the number oflayers to be printed to achieve the three-dimensional structure. Eachlayer file could be printed a predetermined number of times depending onthe desired structure. In some embodiments, each layer file will be thesame. In other embodiments, some layer files could be modified tocorrect for any irregularity on the surface of the substrate. In step1510, printing device 110 could print the modified layer having amodified predetermined thickness onto the substrate.

In step 1512, the structure to be printed may be complete, and theprinting process is finished in step 1514. In some embodiments, thestructure may not be complete, and sensing device 132 may detect thedepth of any resulting cavity after the selected layer has been printed.In step 1516, the next layer to be printed is selected and the processis repeated. The predetermined thickness of a layer could be adjustedbased on the contour map information from the resulting cavity. Printingdevice 110 could print this modified predetermined thickness layer ontop of the previous layer. In some embodiments, this process maycontinue until all of the cavities or irregularities have beencompletely filled. Once the surface of the substrate is substantiallysmooth, the remaining layer files could be printed without beingmodified.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting, and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of the invention.Any feature of any embodiment may be used in combination with orsubstituted for any other feature or element in any other embodimentunless specifically restricted. Accordingly, the invention is not to berestricted except in light of the attached claims and their equivalents.Also, various modifications and changes may be made within the scope ofthe attached claims.

We claim:
 1. A method of printing onto a base, the method comprising:receiving a base on a platform, wherein the base includes a plurality ofcavities; detecting a first depth of each of the cavities; printing aninitial printed layer, wherein the initial print layer only partiallyfills one or more of the cavities; curing the initial printed layer;detecting a second depth of each of the one or more partially-filledcavities; printing a final printed layer, wherein after printing thefinal printed layer, each of the cavities is completely filled; andcuring the final printed layer, wherein after curing the final printedlayer, the final printed layer is substantially flat.
 2. The method ofclaim 1, wherein after detecting the second depth of each of the one ormore partially-filled cavities and prior to printing the final printedlayer, the method further comprises: printing an intermediate printedlayer, wherein the intermediate printed layer only partially fills theone or more partially-filled cavities; and curing the intermediateprinted layer.
 3. The method of claim 1, wherein the first depth of eachof the cavities is substantially the same depth.
 4. The method of claim1, wherein the first depth of at least one cavity is greater than thefirst depth of one or more other cavities.
 5. The method of claim 1,wherein prior to printing the initial printed layer, the method furthercomprises: receiving an image file of a structure to be formed on thebase, wherein the image file includes a predetermined thickness of theinitial printed layer; and generating a modified image file using thefirst depth of each of the cavities, wherein the modified image fileincludes one or more adjusted thicknesses corresponding to the firstdepth of a respective cavity, and wherein one or more of the adjustedthicknesses is less than the first depth of the respective cavity,wherein printing the initial printed layer includes using the modifiedimage file.
 6. A method of printing onto a base, the method comprising:detecting a first depth of each cavity of a plurality of cavities,wherein the cavities are disposed on a base; printing an initial printedlayer, wherein the initial print layer only partially fills at least oneof the cavities; curing the initial printed layer; detecting a seconddepth of each of the at least one partially-filled cavities; printing afinal printed layer, wherein after printing the final printed layer,each of the cavities is completely filled; and curing the final printedlayer, wherein after curing the final printed layer, the final printedlayer is substantially flat.
 7. The method of claim 6, wherein afterdetecting the second depth of each of the at least one partially-filledcavities and prior to printing the final printed layer, the methodfurther comprises: printing an intermediate printed layer, wherein theintermediate printed layer only partially fills one or more of the atleast one partially-filled cavities; and curing the intermediate printedlayer.
 8. The method of claim 6, wherein the first depth of each of thecavities is substantially the same depth.
 9. The method of claim 6,wherein the first depth of at least one cavity is greater than the firstdepth of at least one other cavity.
 10. The method of claim 6, whereinprior to printing the initial printed layer, the method furthercomprises: receiving an image file of a structure to be formed on thebase, wherein the image file includes a predetermined thickness of theinitial printed layer; and generating a modified image file using thefirst depth of each of the cavities, wherein the modified image fileincludes one or more adjusted thicknesses corresponding to the firstdepth of a respective cavity, and wherein one or more of the adjustedthicknesses is less than the first depth of the respective cavity,wherein printing the initial printed layer includes using the modifiedimage file.
 11. A system for printing onto a base comprising: a controlsystem configured to: receive information about depths of cavities on asurface of a base, wherein the received information includes a firstdepth of each cavity of a plurality of cavities; receive an image fileof a structure having a predetermined thickness of a layer to be printedon the surface of the base; adjust the image file based on the firstdepth of the cavities; generate an adjusted image file having a firstadjusted thickness, wherein the first adjusted thickness is less thanthe first depth of one or more cavities; and transmit the adjusted imagefile to a printing device; and the printing device configured to:receive the adjusted image file; and print a base layer directly ontothe base using the adjusted image file, wherein the base layer onlypartially fills the one or more cavities.
 12. The system of claim 11,further comprising a curing device configured for curing the base layerafter the base layer is printed onto the base.
 13. The system of claim12, wherein the control system is further configured to: receiveinformation about depths of the one or more partially-filled cavities,wherein the received information includes a second depth of each cavityof the one or more partially-filled cavities; adjust the image filebased on the second depth of the one or more partially-filled cavities;generate the adjusted image file having a second adjusted thickness; andtransmit the adjusted image file to the printing device; and wherein theprinting device is further configured to: receive the adjusted imagefile; and print a final layer using the adjusted image file, whereinafter printing the final layer, each of the cavities is completelyfilled.
 14. The system of claim 13, wherein the curing device is furtherconfigured for curing the final layer after the final layer is printed.15. The system of claim 14, wherein the second adjusted thickness isgreater than the second depth of the one or more partially-filledcavities.
 16. The system of claim 14, wherein the second adjustedthickness is less than the second depth of the one or morepartially-filled cavities.
 17. The system of claim 16, wherein afterreceiving information about the second depth of each of the one or morepartially-filled cavities and prior to printing the final layer: thecontrol system is further configured to: adjust the image file based onthe second depth of the one or more partially-filled cavities; generatethe adjusted image file having a third adjusted thickness, wherein thethird adjusted thickness is less than the second depth of the one ormore partially-filled cavities; and transmit the adjusted image file tothe printing device; and wherein the printing device is furtherconfigured to: receive the adjusted image file; and print anintermediate layer using the adjusted image file, wherein theintermediate layer only partially fills the one or more partially-filledcavities.
 18. The system of claim 17, wherein the curing device isfurther configured for curing the intermediate layer after theintermediate layer is printed.
 19. The system of claim 11, wherein theimage file is a grayscale file of the structure, and wherein thestructure is a three-dimensional object.
 20. The system of claim 11,further comprising a sensing device configured for detecting the depthsof the cavities.